Interpolymerization products



Patented 14, 1947 2 42 787 cohols used in carrying 2,428,787 INTERPOLYIWERIZA TION PRODUCTS Gaetano' F. DAlelio,

General Electric Company,

New York No Drawing.

Plttsfield, Mass., assignor to a corporation of Application October 31, 1939, Serial No. 302,168

13 Claims. (Cl. 260-42) This invention relates to the production of new materials having valuable and characteristic properties that make them especially suitable for -matter comprising an lnterpolymer (copolymerr orinterpolymers of at least one polymerizable modified or unmodified polyhydrlc alcohol ester of an alpha unsaturated alpha beta polycarboxylic acid (hereafter for brevity designated generally as an unsaturated alkyd resin) with at least one polymerizable polyester obtained by esterifying a non-ethylenic polycarboxyllc acid, e. g., a saturated aliphatic polycarboxylic acid such as'succinic acid, with an unsaturated monohydrc alcohol, e. g., allyl alcohol.

The polyesters of unsaturated monohydrio althe present invention into efiect may be considered .as being members of the class of esters which may be represented by the formula whcre R is a member of the class consisting of hydrogen, unsubstituted hydrocarbon radicals and substitutedhydrocarbon radicals, for instance h drocarbon radicals containing substituent groups such as halogeno, carboxy, carbalkoxy, acyloxy, alkoxy, aryloxy, nitro, acyl,

nitrilo, aldehydo, etc.; 1:. has a numerical value of at least two; andY represents the radical of a non-ethylenic polycarboxylic acid (or an anhydride thereof, if available) containing at least two carboxy groups. Thus. R may be. for exmassive bodies.

dicarboxylic acids, the cyclohexane dicarboxylic acids, the alkyl cycloalkane polycarboxylic acids, etc., and the aromatic polycarboxylic acids, e. g. phthalic, isophthalic, terephthalic, benzoyl phthalic, diphenic and benzophenone-2,4' dicarboxylic acids, etc. Tartaric and citric acids are examples of hydroxy saturated polycarboxylic acids.

A very practical advantage accruing from my invention is that it provides new compositions adapted for the production of cast or molded The unsaturated alkyd resins alone are unsuited, even in the presence of polymerization catalysts such as peroxides, for the preparation of practically useful massive bodies. With or without polymerization catalysts, however, they may be applied in film form and,

under the influence of heat or light, or heat. and light, may be converted in a reasonable time to a cured film. But if effort be made to prepare commercially usefulmassive bodies from the unsaturated alkyds alone, heat treatment even for 24 hours .in the presence of a polymerization catalyst such as super-peroxides usually gives unsuitable materials, that is, they generally lack the properties required for the usual service applications. For example, the cast or molded articles often aresoft, rubbery masses (even after heat treatment for 24 hours at elevated temperatures) or, if hard bodies, frequently are filled with bubbles or show cracks, or both, when cured.

- I have discovered that these and other difliculties ample, any alkyl radical vsuch as methyl, ethyl propyl, isopropyl, butyl, secondary butyl, isobutyl, amyl, isoamyl, hexyl, octyl, etc., any carbocyclic radical such as phenyl, cresyl, halo phenyl, xylyl, tolyl, naphthyl, phenoxy ethyl,.

phenyl propyl, cyclohexyl, orthomethyl cyclohexyl, etc. Examples of Y are the radicals of saturated aliphatic polycarboxylic acids such as oxalic, malonic, succinic, adipic, glutaric, pimelic, sebacic. azelaic, suberic, tricarballylic, tartaric, citric, etc., the radicals of the cyclic polycarboxylic acids, specifically the saturated cycloaliphatlc polycarboxylic acids such as the cyclopropane ,in the production of useful, massive, cast or molded articles from unsaturated alkyd resins can be obviated by forming copolymers of such resins with polyallyl esters of non-ethylenic poly- A carboxylic acids. This was quite surprising and unexpected, as these polyallyl esters when polymerized alone usually are gel-like, friable compositions of very limited applications. There are no difliculties in incorporating a catalyst into the mixed or dissolved components, as usually is the case when efiort is made to polymerize an unsaturated alkyd resin alone, since these polyallyl esters are good dispersion mediums for the usual polymerization catalysts. The copolymerization between the components proceeds satisfactorily, yielding interpolymerization products having properties quite different from the properties of the individual components when anhydrides of such acids.

tion oi the said resin in the said a polymerizable esteriflcation product of a, polyhydric alcohol and an alpha unsaturated alpha beta polycarboxylic acid is first prepared in accordance with technique now well known to those skilled in the alkyd resin art. Any polyhydric alcohol containing at least two esterifiable aliphatic hydroxyl groups, or mixtures of such alco-. hols, may he used in preparing the unsaturated alkyd resin. Examples of such polyhydric alcohols are ethylene glycol. di-. triand tetra! Any alpha unsaturated alpha beta-polycarboxylic acid, or mixtures of such acids, may be reacted with the polyhydric alcohol or alcohols to form the unsaturated alkyd resin. Examples of such polycarboxylic acids are maleic, monohalomaleic, fumaric. monohalofumaric, citraconic, mesaconic, acetylene dicarboxylic, aconitic, ltaconic and its homologues as for instancealpha methyl itaconic acid, alpha, ethyl itaconic acid, alpha alpha dimethyl itaconic acid, etc. If available, anhydrides of these polycarboxylic acids may be employed.

In some cases, instead'of using an unmodified unsaturated alkyd resin I may use a polymerizable unsaturated alkyd resin which has been internally modified by replacing a part, say up to about 75 mol per cent, of the unsaturated polycarboxylic acid with a, non-ethylenic polycarboxylic acid, e. g., a saturated aliphatic polycarboxylic acid such as succinic, adipic, glutaric, pimelic, sebacic,

azelaic, suberic. tricarbaliylic, tartaric. citric, etc.,

cyclic polycarboxylic acids, more specifically the saturated cycloaliphatic, polycarboxylic acids such as the cyclopropane dicarboxylic acids, the cyclohexane dicarboxyiic acids, the alkyl cycloalkane polyearboxylic acids, etc., and the arcmatic polycarboxylic acids, e. g., phthalic, benzoyl phthalic. terephthalic, isophthalic, benzophenom-2,4 dicarboxylic, etc., or with anhydrides of such acids if available.

The term unsaturated alkyd resin as used generallyherein and in the appended claims is intended to include within its meaning both unmodified esterification products of a polyhydric alcohol with'an alpha unsaturated alpha beta polycarboxylic acid and polymerizable esterification products ofthe said components which have been modified, for example, as above briefly described. The terms polycarboxylic acid and "dicarboxylic acid," as used generally herein and in the" appended claims with reference to nonethylenic polycarboxyllc acids and alpha unsaturated alpha beta polycarboxylic acids, are intended'to include 'within their meanings the To achieve copolymerization of the unsaturated alkyd resin with the polyallyl ester, a soluester first preferably is efiected. The polyallyl ester also advantageously may act as the carrier for a small amount of a polymerization catalyst. Examples of polymerization catalysts which may be used are ozone, ozonides, inorganic super-oxides such as oxide, stearyl peroxide, etc., peroxides matic acid series, e. g. benzoyl peroxide, various ethylene glycols, propylene glycol, trimethylene glycol, thiodiglycol, glycerine, pentaerythrito, etc.

merely under the influence oi barium peroxide, sodium peroxide.

acyl'peroxides, e. g. acetyl peroxide, lauryl peroi the arcper-compounds such as perborates, 'persulfates, perchlorates, etcL, aluminum salts such as the halides,.e. 3., aluminum chloride, ta, organic and inorganic acids such as methacrylic acid, bydrofluoric acid, etc.. metal compounds of the unsaturated acids as for instance cobalt and manganese resinates, linoleates, maleates, etc. Benzoyl peroxide is the preferred catalyst. Any suitable amount of catalyst may be used, but in general the catalyst concentration will be within the range of 0.1 to 2.0 percent by weight'ot the whole. j

When rapidity of interpoiymerization between the polyallyl ester and the unsaturated alkyd resin is oi'second'ary importance, copolymerization between these components may be effected heat, light,'or heat and light and in the absence of an accelera-' tor oi. polymerization. The rate of copolymeri zatio'n and the properties of the vary with the time. temperature and, ii a catalyst is used, also with the catalyst concentration. Copolymerization may be eiiected at from. room temperature (20 to C.) to temperatures above 100- C., for example about 130 0., but ordinarily I use temperatures within the range of 60 to 120 C. in causing the'mixed components to interpolygiven by way of illustration. All parts are by weight. Reference is first made to the components, and proportions thereof, used in the preparation of the unsaturated alkyd resin. These resins (identified by letter designations) were copolymerized with various polyally esters in varying amounts, using 1% components of benzoyl peroxide as an accelerator of polymerization. A brief description of the properties of the copolymer after 24 hours interpolymerization at C. is given. I

Example 1 Unsaturated Alkyd Ream Composition A ethylene glycol (23 parts) and itaconic acid (52 I B dietlglcne glycol (106 parts) and itaconic acid pa s C glyoerine (18.4 sland itaconio acid (26 s).

E ethylene gl 00%. parts) itaoonic acid ag l parts) an phthslic anhydride (111.03 parts).

F glycerine (20 parts) itaeonic acid (29 poi-ts) and phthalio anhydride (11 parts a G diethylene dglycol (20 arts) itaconic acid (182 Karts) an suceinic a d (7.08 H et ylene glgcol (20 parts) maleic enhydride (29.4

. parts) an succinic acid (3.3 s). .1

I diethylene glycol (30.6 parts maleic snhydride 17.6 p er-ts) and itaconic acid (16.6 parts K glyges a (18.4 parts) and maleic enhy ide (29.4

L diethylene glycol (30.3 parts maleic snhydride (13.2 parts) and phthal c a ydride (21.7 parts).

M glycerino (26.76 parts) maleic'anhydride (13.72

s) and phthslicanh dride (20.72 parts). N etwylene glycol (18 parts and meleic anhydride 0 dieth y ene glycol (mo parts) and maleic anhydride (147 parts).

A copolymer of ethylene glycol'itaconate and etc., aliphatic final product by weight oi the mixed tureo! about 70 0. and in about 30 minutes a Characteristics of Resin Parts Polyallyl Ester Parts Co lyrner after 24 ours at 70 C.

diallyl succinate... 10 hard, clear. o 90 soft, o aque.

diallyl oxalate". l soft, c ear diallyl succinate. hard, clear. diallyl oxalate...; 90 soft, clear, gel-like. diallyl succinate 90 Do. J diallyl oxalate. 10 hard, clear. do 90 soft, translucent.

diallyl succinate-.. 90 Do. diallyl oxalate. 10 hard, clear. .d0. 10 D0.

do 10 firm, clear. 90 soft, clear. do 10 hard, clear.

diallyl succinate. 10 Do. diallyl oxalate" l0 soft, clear. diallyl succinate.. 10 hard, clear. diillyl oralate.. 10 hard. white, opaque. diillyl succinate 10 Do. diallyloralate 10 clear, hard. diallyl succinate... 10 Do. do... "i..." fairlysol't.

diallyl oxalate. 20 clear, hard. diallyl succinate... 20 Do. diallyl oxalate. 20 Do. diallyl succinate... 20 Do.

Example 2 Compositions were prepared by mixing 90 parts ethylene glycol maleate, specifically resin N described under'Example 1, with 10 parts of the following polyallyl esters in which was incorpor'ated prior to admixture 1 part benzoyl peroxide: diallyl malonate, diallyl-Z-allyl malonate, diallyl, adipate, diallyl glutarate, diallyl azelate and diallyl tartrate. Small samples of the resulting solutions were heated on a 130 C. hot plate, and all were converted into hard, insoluble and iniusible films in less than 60 seconds.

Example 3 In a manner similar to that described under Example 2, and using substantially the same ratics of components, diamethallyl succinate was copolymerized with resins A, B, C, E, F, G, H, I, K, L, M, N and O, yielding insoluble and infusible films in each case.

It will be understood,-of course, that my invention is not limited to the production of copolymers of the particular unsaturated alkyd resins with the particular polyallyl esters of nonethylenic polycarboxylic acids set forth in the above examples and that unsaturated alkyd resins and polyallyl esters of non-ethylenic polycarboxylic acids other than those above given" by way of illustration may be employed in'producing the new interpolymerization products of this invention. Also, polymerization catalysts other than benzoyl peroxide may be employed, for instance accelerators of polymerization such as hereinbefore mentioned.

In certain cases, instead of copolymerizing a single polyallyl ester with a single unsaturated alkyd resin, I may copolymerize a plurality of polyallyl esters of non-ethylenic polycarboxylic acids with a single unsaturated alkyd resinor with a plurality of such resins. In this way it is possible to obtain a composition comprising a mixture of interpolymers best adapted to meet a particular service application,

Although in the foregoing examples I have shown the production of interpolymers by copolymerizing the starting component within the range of, by weight, 10 to per cent of the unsaturated alkyd resin to 90 to 10 per cent of the polyallyl ester, it will be understood, of course, that the invention is not limited to these particular ranges of proportions. The incorporation of a smallamount, e. .g., 3 or 4 per cent, of these polyallyl esters into an unsaturated alkyd resin has a beneficial effect upon such resins, yielding products of improved properties as compared with an unsaturated alkyd resin which has been polymerized in the absence of such an ester. However, somewhat better results usually are obtained when the polyallyl ester constitutes, say, 6 or 8 per cent by weight of, the mixed starting components. Inmost cases the mixed components are so proportioned that the polyallyl ester constitutes from 10 to 90 per cent by weight of the of secondary consideration, the polyallyl ester may constitute, say, 94 or 95%,.or more, by weight of the whole, depending, for example, upon the particular starting components employed and the particular properties desired in the copolymer.

The interpolymerization products of this in-.

vention have a wide range of properties. Depending, for instance, upon the particular unsaturated alkyd resin and the particu ar polyaliyl ester of a non-ethylenic polycarboxylic acid employed, the particular proportions thereof,- the conditions of polymerization (temperature, time, pressure, presence or absence of catalyst, kind of catalyst used, if any, as well as the catalyst concentration, etc.) and the extent of the interpolymerization, they vary from soft, flexible, soluble bodies to hard, rigid masses of varying resistance to solvents. In intermediate stages of copolymerization some of the herein described polymerizable mixtures form fluid compositions of varying intrinsic viscosities and may be so used. For coating or impregnating applications where the presence of a small amount of solvent in the cured composition is not objectionable, the mixed polymerizable materials may be diluted with volatile or non-volatile solvents to viscosities best ample, casting, molding and laminating applica-' .tions, as adhesives, impregnants and surface coating materials. In coating, impregnating and similar applications the mixed components, without added solvent, may be applied to the object to be treated and polymerized as hereinbefore described, with or without the application of pressure, to form the copolymer in situ. They may be used as impregnants for many porous bodies, such as cork, pottery, ielts, or fabricated bodies with, interstices, such asthe windings of electrical coils, netted fibers, inter woven fibrous materials. They also may be used for protectivelycoating impervious articles such resin obtained by esteriflcation amaze? polymerizable materials merizable unsaturated viiride, and succinic acid, and (2) 8. A composition comprising the product po ymerization of a agents, may be cast and molded under heat or under heat and pressure. They also may be molded-by injection. extrusion or compression.

molding technique whereby they are heatand pressure-hardened to yield numerous molded articles of manufacture for industrial, household and novelty uses.

What I claim as new and desire to secure b Letters Patent of the United States, is;

1. The product of polymerization of a mixture of compatible, copolymerizable materials consisting of (1) a polymerizable unsaturated alkyd resin obtained by esteriflcation of a polyhydric alcohol, an alpha unsaturated alpha beta polycarboxylic acid and a pclycarboxylic acid selected from the class consisting oi saturated aliphatic polycarboxylio acids and aromatic polycarboxylic acids, and (2) a polyallyl ester of a saturated aliphatic polycarboxylic acid.

'2. The product of polymerization of a mixture of compatible. copolymerizable materials consisting of an itaconic ester of a polyhydric alcohol and a polyallyl ester of a saturated aliphatic polycarboxylic acid.

3. The product of polymerization of a mixture of compatible, copolymerizable materials comprising 1) a polymerizable unsaturated alkyd of a dihydric alcohol, an alpha unsaturated alpha beta dicarboxylic acid and a saturated aliphatic dicarboxylic acid, and (2) a polyallyl ester of a saturated aliphatic polycarboxylic acid.

4. The product of polymerization of a mixture oi compatible,- copolymerizable materials com! prising (1) a polymerizable unsaturated alkyd resin obtained by esteriflcation of a dihydric alcohol, an alpha unsaturated alpha beta dicarboxylic acid, and an aromatic dicarboxylic acid, and (2) a polyallyl ester of a saturated aliphatic polycarboxylic acid.

5. The product of polymerization of a mixture 01 compatible, copolymerizable materials comprising (1) a polymerizable unsaturated alkyd resin'obtained by esteriflcation of a polyhydric alcohol, an alpha unsaturated alpha beta polycarboxylic acid and a polycarboxylic acid selected from the class consisting of saturated aliphatic polycarboxylic acids and aromatic polycarboxylic acids, and (2) a diallyl ester of a saturated aliphatic dicarboxylic acid.

6. A composition comprising the product 01' polymerization of a mixture of compatible, co-

polymerizable materials comprising an itaconic ester of a dihydric alcohol and a polyallyl ester of a saturated aliphatic polycarboxylic acid.

7. A composition comprising the product ,of polymerization 01' a mixture of compatible, oo-

. comprising (1) a po yaikyd resin obtained by esteriflcation of ethylene glycol, maleic anhydia'llyl oxalate, f mixture of compatible.)

polymerizablematerlals comprising (1) a polymerizable unsaturated alkyd resin obtained it esteriflcatlon o1 glycerine, maleic anhydride, an phthalic anhydride, and (2) diallyl succinate.

9. A composition comprising the product 'of polymerization of a mixture oi compatible, co polymerizable materials comprising ethylene glycol itaconate and diallyl succinate.

10. The method of producing new synthetic compositions which comprises polymerizing a mixture of compatible, copolymerizable materials comprising 1) a polymerizable unsaturated alkyd resin obtained by the esteriflcation oi. a

polyhydric alcohol,

an alpha unsaturated alpha beta polycarboxylic acid and a polycarboxyiic acid selected from the class consisting of saturated aliphatic polycarboxylic acids and aromatic polycarboxylic acids, (2) a polyallyl ester of a saturated aliphatic polycarboxylic acid, and (3) a catalyst for accelerating the ccpolymerization of (1) and (2).

11. The method of compositions mixture of rials comprising hydric alcoh producing new synthetic which comprises polymerizing a compatible, copolymerizable mate- I 1) an itaconic ester 01' a poly- (2) a polyallyl ester of a satpolycarboxylic acid, and (3)11 catalyst for accelerating the copolymerization of (1) and (2).

12. The method of producing new synthetic compositions mixture com urated alkyd which comprises polymerizing a prising (1) a polymerizable unsatresin obtained by esteriflcation of diethylene glycol, maleic anhydride, and phthalic' anhydride, (2) diallyl succlnate, and (3) a catalyst for accelerating the copolymerization 01' (1) and .(2). v

13. The method of producing new synthetic compositions which comprises polymerizing a mixture comprising (1) ethylene glycol itaconate, (2) diallyl succinate, and (3) a catalyst for accelerating the copolymerization of 1) and (2) GAETANO F. DALELIO.

REFERENCES The'following references are of record in the file of this patent:

UNITED- STATES PATENTS Number 

